Support System for a Reclining or Sitting Body

ABSTRACT

A support system including polyurethane layers having different indentation load deflection characteristics and a plurality of zones to vary the level of support in different regions of a reclining or sitting body.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and benefit of U.S. Provisional Application No, 61/781,508, filed Mar. 14, 2013, the entire contents of which are incorporated by reference herein for all purposes.

TECHNICAL FIELD OF THE INVENTION

The present invention is directed toward a support system for a reclining or sitting body. More particularly, the invention relates to a mattress topper, a layer of a mattress, a mattress, or a cushion.

SUMMARY OF THE INVENTION

In one aspect, the invention is directed to a support system for a reclining body, comprising a hexahedron having an upper layer and a lower layer. The lower layer is made from a first synthetic foam having a first side, a second side, a first end and a second end, a top surface and a bottom surface. The upper layer also has at least a first zone, a second zone, and a third zone. The first zone extends from the first end of the upper layer towards the second zone, the second zone is positioned between the first zone and the third zone, and the third zone extends from the second end towards the second zone of the upper layer. In one embodiment, the top surface of the upper layer is substantially planar, and the bottom surface of the upper layer has a plurality of ridges paralleling a plurality of valleys. Each ridge and valley of the upper layer extends from the first side of the upper layer to the second side of the upper layer,

The lower layer of the hexahedron support system is made from a second synthetic foam different from the first synthetic foam of the upper layer. The lower layer parallels the upper layer and has a first side, a second side, a first end and a second end, a top surface and a bottom surface. The lower layer has at least a first zone, a second zone, and a third zone. The first zone of the lower layer extends from the first end of the lower layer towards the second zone, the second zone is positioned between the first zone and the third zone, and the third zone extends from the second end towards the second zone of the lower layer. In one embodiment, the bottom surface of the lower layer is substantially planar, and the top surface of the lower layer has a plurality of ridges paralleling a plurality of valleys. Each ridge and valley of the lower layer extends from the first side of the lower layer to the second side of the lower layer.

The zones of the upper layer of the hexahedron support system according to the invention align with the zones of the lower layer of the hexahedron support system. The plurality of ridges in the top surface of the lower layer interface with the plurality of valleys of the bottom surface of the upper layer. The plurality of valleys in the top surface of the lower layer interface with the plurality of ridges in the bottom surface of the upper layer.

In one embodiment of the invention, the bottom surface of the upper layer of the hexahedron support system interdigitates with the top surface of the lower layer whereby such combination of the upper layer and the lower layer form the support system of the invention.

In one embodiment of the invention, the plurality of ridges and valleys positioned in the first zone of the upper layer and the plurality of ridges and valleys positioned in the first zone of the lower layer are different in number than the plurality of ridges and valleys in the second zone of the upper layer and in the second zone of the lower layer.

In this embodiment of the support system, the plurality of ridges and valleys in the second zone of the upper layer and the plurality of ridges and valleys positioned in the second zone of the lower layer may be different in number than the plurality of ridges and valleys in the third zone of the upper layer and in the third zone of the lower layer.

In a particular embodiment of the support system, one of the upper layer or the lower layer is made from a synthetic foam selected from the group consisting of polyurethane foam, polyurethane gel foam, and viscoelastic polyurethane foam, and the other of the upper layer or lower layer is made from a material having a different indentation load deflection than the material of the other layer. For example, the upper layer comprises a polyurethane foam having one indentation load deflection and the lower layer comprises a polyurethane foam having another indentation load deflection. Alternatively, the upper layer comprises a polyurethane material and the lower layer comprises a material comprising a higher indentation load deflection than the polyurethane material of the upper layer.

The ridges of the support system described above may have a radius or an apex having an acute angle, or an obtuse angle in cross-section.

In one embodiment of the invention, the depth of the valleys in the lower layer is in the range of about 0.5 to 24 inches. In another embodiment of the invention the depth of the valleys in the upper layer is about 0.5 inches to 24 inches. The invention may feature in a particular embodiment, one of the lower or the upper layer having a thickness that is one to seven times as thick as the other layer.

In a particular embodiment of the support system described above, the bottom surface of the lower layer of the support system is positioned adjacent to and parallel to a top surface of a base layer.

In an alternative embodiment of the support system described above. the top surface of the upper layer of the support system is positioned adjacent to and parallel to a surface layer.

In yet another embodiment of the support system described above, the bottom surface of the lower layer of the support system is positioned adjacent to and parallel to a top surface of a base layer and the top surface of the upper layer of the support system is positioned adjacent to and parallel to a surface layer.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a perspective view of a support system according to one embodiment of the invention;

FIG. 2 illustrates a perspective exploded view of the support system illustrated in FIG. 1 according to one embodiment of the invention;

FIG. 3 illustrates a side view of the support system according to the embodiment of the invention illustrated in FIG. 1;

FIG. 4 illustrates an end view of the system according to the embodiment of the invention illustrated in FIG. 1;

FIG. 5 illustrates another embodiment of the support system according to the invention;

FIG. 6 illustrates yet another embodiment of the support system according to the invention.

DESCRIPTION OF THE INVENTION

The following description is of the best contemplated modes of carrying out exemplary embodiments of the invention. The description is not to he taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.

Various inventive features are described below that can each be used independently of one another or in combination with other features.

In general the invention is directed to a support system for a reclining or a situ mammalian body, such as a human body.

Broadly, embodiments of the present invention generally provide a support system for a reclining or sitting body. The support system may be, for example, a mattress topper, a mattress, or a cushion, for example a seat cushion. In one embodiment the support system of the invention provides one or more layers of a mattress, in another embodiment the support system provides a topper for a mattress, in yet another embodiment the support system provides a mattress, in still another embodiment the support system provides a seat cushion for a chair, for example, an auto seat or an airplane seat.

Aspects of the present invention provide a hexahedron typically greater in length than in width, having an upper layer comprising a synthetic foam material having an indentation load deflection, a lower layer comprising a synthetic foam material and having an indentation load deflection different than the indentation load deflection of the upper layer, the upper layer having a plurality of zones, one or more zones comprising ridges and valleys, that interdigitate with a corresponding plurality of zones, one or more zones comprising ridges and valleys, in said lower layer. The upper layer combines with said lower layer by mating the zones of the upper layer with the zones of the lower layer to thereby form a synthetic foam hexahedron support system.

A mattress topper as used herein shall mean a layer to be applied over a mattress.

As used herein, a lower layer shall mean a layer positioned between the earth's center of gravity and an upper layer.

As used herein, a top surface of an object shall mean a surface further away from the earth's center of gravity than the bottom surface of said object.

As used herein, the bottom surface of an object is the underside of the object.

As used herein, indentation load deflection shall mean a measurable amount of deflection in response to an applied force.

Referring now to FIG. 1, a perspective side view of a support system 10 according to an embodiment of the present invention is generally illustrated, Support system 10 has a first end 11, a second end 13, a first side 15, a second side 17, a top surface 19, and a bottom surface 21. Typically the ends 11, 13 are shorter in length than the sides 15, 17, The shape of the support system 10 is substantially a hexahedron having an upper layer 20 and a lower layer 30. The thickness or depth of the upper layer 20 may he the same as or different than the thickness or depth of the lower layer 30. Synthetic foam materials that may be used for either or both the upper and lower layer include, for example, polyurethane foam, polyurethane gel foam, and viscoelastic polyurethane foam, or combinations thereof.

Referring now to FIG. 2 and FIG. 3, support system 10 includes an upper layer 20 and a lower layer 30. Each of the upper layer 20 and the lower layer 30 of the support system 10 have a plurality of zones 40 extending from the first end 11 to the second end 13 of the support system 10. In one embodiment, in each of the upper layer 20 and the lower layer 30, the support system 10 may have a first zone 40, a second zone 4′, a third zone 40″, a fourth zone 40′″, a fifth zone 40″″, a sixth zone 40″″′, and a seventh zone 40″″″. Other zones, for example, from 3-9 zones, preferably 7 zones, extend from the first end 11 to second end 13 of the support system 10 in various embodiments of the invention. In one embodiment of the invention, the number and position of the zones in the upper layer 20 are the same as the number and position of zones in the lower layer 30. The number of zones illustrated in FIG. 2 and FIG. 3 is merely exemplary and does not limit the possible number of zones or the distribution of the zones from the first end 11 to the second end 13 of the support system 10 according to the invention.

With continued reference to FIG. 2, the top surface 19 of the upper layer 20 is substantially planar, the bottom surface 9 of the upper layer 20 comprises one or more substantially planar surface zones, e.g., zones 40, 40″, 40″″ and 40″″″ interrupted by a plurality of zones, e.g., zones 40′, 40′″ and 40″″′, featuring a plurality of ridges 50 paralleling a plurality of valleys 51, each ridge and valley extending from the first side 15 of said upper layer 20 to said second side 17 of said upper layer 20. Thus, first zone 40 of said upper layer 20 extends from first end 11 of the support system 10 to the second zone 40′, and second zone 40′ extends from the interface of the first zone 40 with the second zone 40′ to the third zone 40″, and so on through zone 40″″″.

As illustrated in FIG. 2, the bottom surface 21 of said lower layer 30 is substantially planar, the top surface 14 of said lower layer 30 comprises one or more substantially planar zones, e.g., zones 40, 40″, 40″″ and 40″″″ interrupted by a plurality of zones, e.g., zones 40′, 40′″ and 40″″′, featuring a plurality of ridges 50 paralleling a plurality of valleys 51, each ridge and valley extending from the first side 15 of said lower layer 30 to said second side 17 of said lower layer 30. Thus, first zone 40 of the lower layer 30 extends from first end 11 of the support system 10 to the second zone 40′, and second zone 40′ extends from the interface of the first zone 40 with the second zone 40′ to the third zone 40″, and so on through zone 40″″″.

With reference to the side view of the support system illustrated in FIG. 3, the zones of the upper layer 20 are aligned with the zones of the lower layer 30, such that the plurality of ridges in the top surface 1.4 of the lower layer 30 interface with the plurality of valleys of the bottom surface 9 of the upper layer 20 and the plurality of valleys in the top surface 14 of the lower layer 30 interface with the plurality of ridges in the bottom surface 9 of the upper layer 20 (also see FIG. 2). The bottom surface 9 of the upper layer 20 interdigitates with the top surface 11 of the lower layer 30 whereby such combination of the upper layer 20 and the lower layer 30 form the support system 10.

With continued reference to FIG. 2 and FIG. 3, in one embodiment of the invention, second zone 40′ of support system 10, for example, is intended for a reclining user's head or upper body, fourth zone 40′″, for example, is intended for a reclining users mid-body, and sixth zone 40′″″, for example, is intended for a reclining user's lower body.

Each zone 40 n extends in the range of about 14.3-33.3% of the distance of the long axis between the first end 11 and the second end 13 of the support system 10.

For example, in the embodiment illustrated in FIG. 3, each of the exemplary seven zones extend approximately 14.3% of the length of the support system between the first end 11 and the second end 13 of the support system 10. Accordingly, zone 40, for example, extends from the first end 11 to 14.3% of the length of the support system 10 from the first end 11 toward the second end 13. Second zone 40′ extends from the interface of the first zone 40 and second zone 40′, to third zone 40′ and comprises an additional 14.3% of the length of the support system 10 from the first end 11 toward the second end 13, and so on. Thus first zone 40 and second zone 40′ together extend to 28.6% of the length of the support system from the first end 11 to the second end 13. The length of the zones in each layer may be the same or different.

In one embodiment according to the invention, upper layer 20 and lower layer 30 are made from different synthetic foam materials. Typically, lower layer 30 comprises a material having a higher indentation load deflection than the material of upper layer 30. For example, one layer may be any combination of 0.75 pounds to 3.5 pounds polyurethane foam having an indentation load deflection in the range of 08 to 75, and/or 1.2 pounds to 8.0 pounds viscoelastic polyurethane foam having an indentation load deflection of 05 to 25.

Each layer of the support system is profile cut. As illustrated in FIGS. 1 and 3, upper layer 20 is laminated to lower layer 30 by adhering the bottom surface 9 of the upper layer 20 to the top surface 14 of the lower layer 30. This combination can be made up of contoured cut sheets of polyurethane foam that are in the range of about 1.0 inches to 4.0 inches thick which when laminated to the second part would create a support system with a total thickness of 1.5 inch to 15 inches, preferably 1.5 inches to 8 inches, more preferably, 3 inches-5 inches. in one embodiment of the invention, the upper layer has a different thickness than the lower layer.

In one embodiment of the invention, the height of each ridge 50 is in the range of about 0.5 inches to 24 inches, preferably 1-2 inches. The height of the ridges may be the same in each zone, vary within a zone, or may vary from zone to zone.

The depth of each valley 60 is in the range of about 0.5 inches to 24 inches, preferably 1-2 inches. Alternatively, the depth of the valleys may be the same in each zone, vary within a zone, or may vary from zone to zone.

The peaks of the ridges and the bottom of the valleys each may form an acute angle, obtuse angle, or may have a radius.

In one embodiment of the invention, as shown in FIG. 3, the bottom surface 9 of a zone in the upper layer 20, and the top surface 14 of a zone in the lower layer 30 may be substantially planar.

Support system 10 has a support gradient generated by the use of different synthetic materials having indentation load deflection in the upper layer that is different than the indentation load deflection in the lower layer and by the various zones that extend along the length of the support system.

FIG. 5 illustrates a perspective view of another embodiment of the present invention. As shown, support system 10 may be a top layer 22 over a base layer 26. Top layer 22, for example, a mattress topper, includes the upper layer 20 and lower layer 30 of the support system 10 described by any of the embodiments above and generally illustrated in FIG. 1. Base layer 26 may be made from a material, for example, such as a synthetic foam, mesh, fiber, or padding and has a length and width similar to the top layer 22.

FIG. 6 illustrates a perspective view of yet another embodiment of the present invention. Support system 10 may be an intermediate layer 28 positioned between the base layer 26 and a surface layer 24. Intermediate layer 28 includes the upper layer 20 and lower layer 30 of the support system 10 described by any of the embodiments above and generally illustrated in FIG. 1. Surface layer 24 and base layer 26 may be made from a synthetic material, for example, a synthetic foam, mesh, fiber, or padding and has a length and width similar to the intermediate layer 28.

Other arrangements of support system 10 with none to, for example, 5 layers of synthetic material above and/or below support system 10 are also contemplated by the invention and are not limited to the illustrated arrangements.

According to exemplary embodiments of the present invention, support system 10 may have varying lengths and widths corresponding to standard dimensions for American or European support systems for a reclining or sitting person.

It should be understood that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. 

What is claimed is:
 1. A support system for a reclining body, comprising: a hexahedron comprising, an upper layer comprising a first synthetic foam, said upper layer comprising a first side, a second side, a first end and a second end, a top surface and a bottom surface, said upper layer further comprising at least a first zone, a second zone, and a third zone, said first zone extending from the first end of said upper layer towards the second zone, said second zone positioned between the first zone and the third zone, said third zone extending from said second end towards said second zone of said upper layer, the top surface of said upper layer being substantially planar, the bottom surface of said upper layer comprising a plurality of ridges paralleling a plurality of valleys, each ridge and valley extending from said first side of said upper layer to said second side of said upper layer, and, a lower layer comprising a second synthetic foam different from the first synthetic foam of said upper layer, said lower layer paralleling said upper layer and comprising a first side, a second side, a first end and a second end, a top surface and a bottom surface, said lower layer further comprising at least a first zone, a second zone, and a third zone, said first zone extending from the first end of said lower layer towards the second zone, said second zone positioned between the first zone and the third zone, said third zone extending from said second end towards said second zone of said lower layer, the bottom surface of said lower layer being substantially planar, the top surface of said lower layer comprising a plurality of ridges paralleling a plurality of valleys each ridge and valley extending from said first side of said lower layer to said second side of said lower layer, said zones of said upper layer align with said zones of said lower layer, wherein said plurality of ridges in said top surface of said lower layer interface with said plurality of valleys of said bottom surface of said upper layer, said plurality of valleys in said top surface of said lower layer interface with said plurality of ridges in said bottom surface of said upper layer, and wherein the bottom surface of said upper layer interdigitates with said top surface of said lower layer whereby such combination of said upper layer and said lower layer form said support system.
 2. The support system of claim 1 wherein said plurality of ridges and said plurality of valleys positioned in said first zone of said upper layer and said plurality of ridges and valleys positioned in said first zone of said lower layer are different in number than the plurality of ridges and valleys in said second zone of said upper layer and in said second zone of said lower layer.
 3. The support system of claim 2 wherein said plurality of ridges and said plurality of valleys in said second zone of said upper layer and said plurality of ridges and valleys positioned in said second zone of said lower layer are different in number than said plurality of ridges and valleys in said third zone of said upper layer and in said third zone of said lower layer.
 4. The support system of claim 1 wherein said upper layer comprises a polyurethane material comprising an indention load deflection and said lower layer comprises a material comprising an indention load deflection wherein said indentation load deflection of said lower layer is higher than the indention load deflection of the polyurethane material of said upper layer.
 5. The support system of claim 1 wherein one or more of said plurality of ridges comprise a radius in cross-section.
 6. The support system of claim 1 wherein one or more of said plurality of ridges comprise an apex comprising an acute angle in cross-section.
 7. The support system of claim 1 wherein one or more of said plurality of ridges comprise an apex comprising an obtuse angle in cross-section.
 8. The support system of claim
 1. wherein the thickness of one of the lower or upper layer is one to seven times as thick as the other layer.
 9. The support system of claim 1 wherein the depth of said valleys in said lower layer is in a range of about 0.5 inches to about 24 inches.
 10. The support system of claim 1 wherein the depth. of said valleys in said upper layer comprises 0.5 inches to 24 inches.
 11. The support system of claim 1 wherein said upper layer comprises a polyurethane foam comprising one indentation load deflection and said lower layer comprises a polyurethane foam comprising another indentation load deflection.
 12. The support system of claim 1 wherein of said a synthetic foam from one of said upper layer or said lower layer is selected from the group consisting of polyurethane foam, polyurethane gel foam, and viscoelastic polyurethane foam and the other of said upper layer or lower layer comprises a material having a different indentation load deflection than the other layer.
 13. The support system of claim 1 wherein a base layer is positioned adjacent to and parallel to said bottom surface of said lower layer,
 14. The support system of claim 1 wherein a surface layer is positioned adjacent to and parallel to said top surface of said upper layer.
 15. The support system of claim 1 wherein a surface layer is positioned adjacent to and parallel to said top surface of said upper layer and a base layer is positioned adjacent to and parallel to said bottom surface of said lower layer. 